Cummins/Onan 3.6MKY / 4MKY — Generator Assembly

Repair & overhaul

For the Cummins/Onan 3.6MKY / 4MKY, from the Cummins/Onan service manual.

Applies to: Cummins/Onan 3.6MKY, Cummins/Onan 4MKY

Procedure

1. Slide the stator into the generator housing with the output connector aligned; install stator through bolts.
2. Align the pin in the rotor shaft with the crankshaft notch and slide the rotor on; make sure seated.
3. Plug in both stator wire connectors.
4. Lubricate the endbell O-ring, verify brushes are held with wire, and install the endbell onto the rotor bearing.
5. Center the brush block on the slip rings and tighten the mounting screws; remove the wire.
6. Connect the F2 lead to the outer brush terminal and F1 to the inner brush terminal; connect magneto wires.
7. Install the fan hub assembly with the key and the rotor through bolt and washer; tighten to specification.
8. Install the air housing assembly.
9. Remove the wooden block and lower the genset.
10. Install the muffler with new gaskets and install the generator and engine to base bolts.
11. Reconnect load leads, fuel pump leads, and ground terminal.
12. Install the voltage regulator and control assembly; reconnect start solenoid leads and P4 and J1 connectors.
13. Inspect all connections, install the enclosure cover, and reinstall the genset in the boat.
14. Fill the crankcase with oil (see the Operator's Manual).

Source: Cummins/Onan service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.

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